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Power Stak
PPS2200-62NAS
Installation, Operation
and Service Manual
Model Number ___________________
Serial # _________________________
Date Placed in Service _____________
IMPORTANT: READ CAREFULLY
BEFORE INSTALLING OR OPERATING LIFT
Part orders are subject to a $50 minimum charge.
AUGUST 2012
Presto Lifts Limited Power Stacker Warranty Policy
Presto Lifts warrants the Power Stacker against defects on the mast, fork carriage, chains, pumps,
DC motors, controllers, cylinders and wiring harnesses from faulty material and workmanship for a
period of one (1) year from the date of invoice.
All wear items such as batteries, wheels, motor brushes, seals, bearings, hydraulic hoses, all switches,
battery chargers and forks have a limited warranty against defects in faulty material and workmanship
for a ninety (90) day period from the date of invoice and 30 day limited warranty on labor. Please
note that prior authorization from Presto Lifts is required on all warranty work.
limited warranty. Presto Lifts will elect to repair or replace a defective component without charge,
if any components should become defective within the limited warranty period. Proof of purchase is
required for warranty. The charge for shipping the defective component is the responsibility of the
buyer and must be accompanied with an RGA number. The shipping charge to return the component
to the buyer is the responsibility of Presto Lifts, Inc.
This limited warranty does not cover labor expense for removal or reinstallation of components
after thirty days. This limited warranty shall not cover, among other things: damages resulting
from foreign matter or water, failure to provide reasonable and necessary maintenance, and if
applicable, use of product while charger is plugged into an AC outlet, or failure to follow operating instructions. The limited warranty is not valid for damage resulting from negligence, accident,
unreasonable use, abuse or misuse, exceeding data plate capacities or altering the product without
Presto Lifts authorization.
Presto Lifts expressly disclaims and excludes any liability for consequential, incidental, indirect
the operation or failure of this product.
Presto Lifts makes no representation that this product complies with local, state, or federal safety/
product standards codes. Should this product fail to comply in any way with those codes, it shall
not be considered a defect of materials or workmanship. Presto Lifts shall not be held liable for any
damages resulting from noncompliance. It is the dealer’s responsibility to exercise this limited warlimited warranty obligations for products.
This manual was current at the time of printing. To obtain the latest, most updated version, please contact the
rent Owner’s Manuals to print.
PRESTO OWNER’S MANUAL
Page 2
POWER STAK
TABLE OF CONTENTS
S E C T I O N 1:
Limited Warranty ................................................................................................................................................2
Introduction .........................................................................................................................................................5
S E C T I O N 2:
Safety .............................................................................................................................................................. 5-6
S E C T I O N 3:
Installation...........................................................................................................................................................7
A. Inspection ....................................................................................................................................................7
B. Removing from Pallet ..................................................................................................................................7
C. Preparation for Use.......................................................................................................................................7
Wheel Traction and Straddle Leg Set-Up ...........................................................................................................8
S E C T I O N 4:
Operation.............................................................................................................................................................9
A. Operating Instructions ...................................................................................................................................9
B. Daily Operations Maintenance Checks .......................................................................................................10
Suggested Daily Operator Checklist .................................................................................................................11
S E C T I O N 5:
Battery Maintenance .........................................................................................................................................12
A. Preparing to Charge a Battery ....................................................................................................................12
B Charging the battery ....................................................................................................................................12
C. Warnings and Battery Info...........................................................................................................................12
D. Battery maintenance....................................................................................................................................12
E. Charger Operations ......................................................................................................................................12
S E C T I O N 6:
Maintenance ......................................................................................................................................................13
A. Weekly Operations Maintenance Checks....................................................................................................13
B. Monthly Operations Maintenance Checks .................................................................................................13
S E C T I O N 7:
Troubleshooting .......................................................................................................................................... 13-14
ORDERING REPLACEMENT PARTS ...........................................................................................................................45
RESTOCKING POLICY ..................................................................................................................................................46
RETURN GOODS AUTHORIZATION ..........................................................................................................................47
LIST OF TABLES:
Table 1: PPS2200-62NAS Assembly (Prior to November 2008) .......................................................... 16
Table 2: Recommended Spare Parts List PPS2200-62NAS ........................................................ 44
PRESTO OWNER’S MANUAL
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POWER STAK
LIST OF FIGURES:
Figure 1:Operational Buttons.......................................................................................................... 7
Figure 2: PPS2200-62NAS Exploded View (Prior to November 2008) ................................................ 15
Figure 3: PPS2200-62NAS Exploded View (November 2008 to Present) ............................................ 17
Figure 4: Cylinder View (Prior to November 2008) ............................................................................... 18
Figure 5: Cylinder View (November 2008 to Present) ........................................................................... 19
Figure 6: Caster Wheel Assembly (Prior to November 2008)............................................................... 20
Figure 7: Caster Wheel Assembly (November 2008 to Present) ........................................................... 21
Figure 8: Drive Wheel Assembly .................................................................................................. 22
Figure 9: Control Pod .................................................................................................................. 23
Figure 10: Steering Assembly (Prior to May 2007) ............................................................................. 24
Figure 11: Steering Assembly (May 2007 to August 2008) ................................................................... 25
Figure 12: Steering Assembly (August 2008 to Present)...................................................................... 26
Figure 13: Power Unit Assembly (Prior to November 2008) ................................................................. 27
Figure 14: Power Unit Assembly (November 2008 to Present) ............................................................. 28
Figure 15: PPS2200-62NAS Carriage Assembly (November 2008 to Present) .................................... 29
Figure 16: Labels & Precautionary Warnings ............................................................................... 30
Figure 17: Electric Control Panel (Prior to November 2008) ................................................................ 31
Figure 18: Electric Control Circuit (Prior to November 2008) ............................................................... 32
Figure 19: Wiring (Prior to November 2008) ......................................................................................... 33
Figure 20: Wiring Diagram (Prior to November 2008) .......................................................................... 34
Figure 21: Wiring Diagrams (November 2008 to Present) .................................................................... 35
Figure 22: Wiring Diagrams (November 2008 to July 2011) .................................................................. 36
Figure 23: Wiring Diagrams (August 2011 to Present) ......................................................................... 37
Figure 24-29: Wiring Diagrams (November 2008 to Present) .......................................................... 38-43
PRESTO OWNER’S MANUAL
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POWER STAK
SECTION 2
SECTION 1
SAFETY
INTRODUCTION
This manual attempts to provide all of the information
necessary for the safe and proper installation, operation
and maintenance of Presto Lifts Inc. battery operated,
Power Stak. It is important that all personnel involved
with the installation, maintenance or operator of the
stacker read this manual. Additional manuals are available upon request or at www.PrestoLifts.com.
Each Presto stacker is equipped with nameplate, serial
numbers when ordering parts or requesting further
information.
The Presto stackers are designed for lifting, lowering and positioning a wide variety of loads. WHERE
UNIQUE SITUATIONS ARISE, WHICH ARE NOT
COVERED IN THIS MANUAL, CALL PRESTO
LIFTS FOR FURTHER INSTRUCTIONS.
The battery operated stackers are designed for inplant/non-hazardous locations only. They can be used
in a 8' or larger aisle. These units are not for personnel
lifting.
powered stacker. Federal law states that only properly trained operators are permitted to operate a
powered industrial stacker and that your employer
(OSHA 1910.178 29QFR-7-1-06 Edition)
Presto lifts does not offer operator training. Operator training programs may be offered by your
local Presto Lifts dealer or obtained online. Enter,
"powered industrial truck operator training" into
a search engine.
The battery operated stackers are very powerful lifts
capable of doing large amounts of work.
DO NOT OPERATE THESE LIFTS WITHOUT
CAREFULLY READING THIS MANUAL. In order
to provide for the safe operation of these stackers,
may occur during the maintenance and use of these
lifts. For safety reasons these units are designed to be
serviced or repaired in the fully lowered position. If
performed properly, this will greatly reduce the possibility of injury.
WARNING!
When servicing the unit:
1. Key should be in "OFF" position.
2. E-stop should be depressed.
3. Disconnect the batteries at the terminals.
Do not perform any repair work on lifts if
there is a load on the forks or platform.
Do not perform any repair work if the forks
or platform is in the raised position.
All personnel must stand clear of the lift
while in motion.
Do not put hands or feet under the forks or
platform.
Do not stand underneath the forks or platform.
Do not stand in front of the stacker while in
motion.
Do not stand, sit or climb on the lift.
Do not use the lift on soft, uneven or unstable
surfaces.
Do not exceed the load center or capacity.
PRESTO OWNER’S MANUAL
Page 5
POWER STAK
WARNING!
You or others around you can be seriously injured
or even killed if you don't use this stacker correctly.
Read and obey all warnings and instructions in this
manual and on the stacker. It is your responsibility before starting work to make sure it is in good
working order.
Always be alert to the area around you and watch where
you are walking. Be careful that you don't get pinned
as a wall or post.
Watch your hands and feet. A foot or hand
be crushed or even cut off.
the control handle and be careful when changing
direction of travel. Keep your feet clear of the
stacker.
Keep the stacker under control at all times.
Operate at a speed that allows you to stop safely.
Be even more careful on slippery or uneven surPerform all stacker movements smoothly and
at a speed that will give you time to react if an
emergency occurs.
WARNINGS
DO NOT use this stacker until you have been trained
and authorized to do so.
DO NOT operate until you have read all warnings and
instructions.
DO NOT exceed load center or load weight capacities
(check capacity plate).
DO NOT operate until you have checked the conditions of the stacker: lift systems, forks, chains, and
cables.
DO NOT use if any part is damaged, worn or not working properly.
DO NOT use on ramps or inclines. Only smooth level
surfaces.
DO NOT use for lifting or carrying people.
DO NOT handle unbalanced, unstable or loosely
stacked loads.
DO NOT travel with forks or platform in an elevated
position.
DO NOT handle tall, unsecured or unstable loads that
could fall.
DO NOT allow people to stand or pass under forks or
platform with or without load.
DO NOT operate when parts of anyone’s body may be
close to mast structure or any moving parts.
DO NOT drop loads on platform or forks.
DO NOT alter or modify this stacker in any way.
be crushed or even killed. To prevent injury, know
where you are at all times and follow the rules of safe
stacker operation.
Be careful when working around docks,
dockboards and trailers. Stay away from the
edge of docks and ramps. Check to make sure the
wheels of truck or trailers are chocked.
Travel with the load or forks close to the
ground. Watch for overhead obstructions. Perform all stacker movements smoothly and at a
speed that will give you time to react in an emergency.
Keep your hands and feet away from all moving parts such as masts, chains, forks or wheels.
Never stand on or under the forks, or allow
anyone else to stand on or under them. Never ride
on the stacker or allow anyone else to ride. There
is no safe place to sit or stand.
Before you leave your stacker, be sure to
with the key.
PRESTO OWNER’S MANUAL
Page 6
POWER STAK
SECTION 3
INSTALLATION
A. INSPECTION:
Upon receipt of the stacker, inspect the equipment completely to determine if there is any shipping damage,
and that the lift is complete. Presto tests and inspects
every piece of equipment prior to shipment. If damage
company. Do not use the stacker if there appears to be
any damage. With the stacker in a lowered position,
check the following:
Check for signs of damage especially to the
back cabinet that houses the battery, electrical/
hydraulic power pack.
Check all electrical and hydraulic connections for tightness.
Remove back panel.
1. Turn key switch to "OFF" position.
2. Push in E-stop and unscrew the red knob,
3. Lift off back panel. There is enough wire
to the key switch to allow the panel to be set
aside.
Inspect for any bent or damaged parts.
B. REMOVING FROM PALLET
Each of the Presto stackers is shipped out on a pallet or
skid. Prior to removing the unit from the pallet or skid,
remove all tie down straps and packaging. Visually
inspect the unit as closely as possible.
With an overhead hoist or forklift, carefully pick up the
unit taking into consideration the center of gravity of the
unit. If you choose to pick the unit with an overhead
hoist, use a nylon sling and hoist with a minimum of
2,000-lb. capacity. The nylon sling will not do any damage to the steel construction of stacker. Pick the unit
up. On conventional masts use the top crossmember of
the lift. On narrow masts the cover must be removed
to access lifting equipment. Be careful of the stacker
swinging once fully lifted off the pallet or skid. Have
all personnel completely cleared from the area.
Pick the unit up approximately six inches above the
pallet or skid. Once raised, remove the pallet or skid
from below the lift. Do not move the lift around in the
air. Lower the stacker on the ground.
C. PREPARATION FOR USE
This stacker left our factory in new condition. It has been
inspected and weight tested to assure all performance
standards have been met.
Visually inspect the stacker for damage. Check for attachments and accessories that may have been ordered.
If there is any damage or missing parts, report it to your
carrier and your Presto dealer immediately.
Remove all metal/plastic bands, cardboard and other
material used for shipping purposes.
Check to see if chains are in place, and that the lift system is in working order. Inspect for oil leaks.
See instructions for removing back panel on pg. 5.
Connect battery cable. Check cables and wires on battery charger as well as battery.
Figure 1: Operational buttons
BELLY BUTTON SWITCH
LIFT UP
LIFT DOWN
HORN
SPEED CONTROL
DIRECTION CONTROL
PRESTO OWNER’S MANUAL
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POWER STAK
CRITICAL PROCEDURE FOR PROPER WHEEL TRACTION
Proper Drive Wheel traction is obtained for the PowerStak Straddle unit using this Procedure
Rubber Drive Wheels are available through special order. Please contact Customer Service at Presto
Lifts 1-800-343-9322
When any PowerStak is operated on a wet, oily, powdery, sandy or non-uniform liquid or granular surface
Drive Wheel traction performance will be affected and loss of traction will occur.
SET-UP PROCEDURE FOR POWERSTAK STRADDLE LEGS
NOTE: STRADDLE LEGS MUST BE ADJUSTED IN ACCORDANCE WITH THIS PROCEDURE
1.
2.
the pallet or load, up to a maximum of 50 inches inside width)
3. Be sure to fully loosen all bolts before moving stabilizing legs. Adjust one stabilizer leg at a time – using a pry
bar, pinch bar, rubber mallet etc. move the straddle leg out from the base tube to the desired position. Do not
4. Adjust second Straddle Leg – using a pry bar, pinch bar, rubber mallet etc. move the straddle leg out from inside
the base tube to the desired straddle width position.
5. Straddle Legs must be symmetrically adjusted, both legs adjusted to the same extended dimension!
CRITICAL – STRADDLE BOLT TIGHTENING SEQUENCE & PROCEDURE
Set up procedure for PowerStak Straddle legs with 3 or 4 Bolts:
5½"
Bolt
Bolt
Bolts
Back off all bolts and follow steps.
NOTE:
When adjusted correctly, white
line cannot be seen.
First - tighten Bolt 1 to 85 foot pounds.
Second - tighten Bolt(s) 2 to 85 foot pounds.
Third - tighten Bolt 3 to 25 foot pounds - NOT 85.
Last - securely tighten all lock nuts.
PRESTO OWNER’S MANUAL
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POWER STAK
SECTION 4
OPERATION
A. OPERATING INSTRUCTIONS:
AUTHORIZED OPERATORS SHOULD READ
AND UNDERSTAND ALL INSTRUCTIONS,
PRECAUTIONS AND WARNINGS.
IMPROPER USE OF THIS LIFT TRUCK
COULD RESULT IN INJURY AND/OR
DAMAGE TO LOAD AND EQUIPMENT.
To Raise and Lower:
There are two buttons located on both sides of the
handle. The inside one is for raising the forks. The
outside one is for lowering the forks. When operating,
always make sure the load being lifted is within the
loading capacity of your stacker and the load has been
stacked safely on the pallet. Also, make sure that the
length of the forks corresponds to the length of the pallet. In this way, the load rollers will place themselves
in the opening at the end of the pallet, so that when you
raise the forks, you will not break the bottom boards
of the pallet. Always make sure that when entering the
pallet that the forks are in the fully lowered position.
Be careful when lifting pallets that are too short or too
long for the stacker. It might destroy your pallet by
breaking the bottom boards, and if the forks project
through the end of the pallet, the tips of fork may go
into the next pallet that is behind the pallet that you are
lifting, which may bend the tips of forks and overload
the capacity of the stacker.
Electric Brake:
Your stacker is equipped with an electric magnetic
brake. The brake is applied when the handle is in its
vertical position between 10 – 15 degrees and lowered
position between 80 – 90 degrees. The brake could be
released when you pull down the handle at any point
between 15 – 80 degrees. Always make sure the brake is
released before operating the stacker. When the stacker
is running, you could brake the stacker by raising the
handle to its vertical position or lowering the handle to
the opposite direction, the change in direction of the
motor will slow down, stop, and reverse the direction
of stacker. When parked, always put the handle in the
full vertical position with the brake applied and the
forks in lowered position.
Reversing Safety:
At the end of the handle there is a large, red reversing
bar (belly button switch) that is designed to protect
the operator from injury. When the operator runs the
stacker backwards, and the end of the handle comes
in contact with the operator’s body, the stacker will
automatically reverse direction and travel away from
the operator. When the reversing safety bar comes in
contact with your body during operation, immediately
handle up to its vertical position or down to its lowest
position and the brake is on. The reversing safety bar
will automatically resume to its original position after
being activated.
Horn:
As standard equipment, a horn that is located on the
top of the handle.
Travel Function:
control CW towards the forks, the stacker runs forwards
CCW towards you, the stacker runs backwards in the
clears any obstruction when traveling, and that your path
of travel is clear of people. Never carry loads above the
loading capacity of the stacker. It is suggested that when
traveling without a load, the forks be in the lowered
position. The speed of the stacker is increased by the
like a throttle. When you release your hand from the butposition and the speed of the stacker will slow down.
PRESTO OWNER’S MANUAL
Page 9
POWER STAK
Inspect the lift for damaged or worn parts.
Do not use if not in safe operating condition.
Use lift on hard level surfaces only.
Make sure load is evenly distributed, not
loose or unstable, and is as far back on platform
or forks as possible. Do not pick up loads on tips
or forks or edge of platform.
For fork models, adjust forks to the maximum practical width. Pick up loads on both
forks.
Do not overload. Check load center and load
weight capacities on the nameplate.
Make sure travel and work area is clear of
obstructions.
Check overhead clearance before lifting loads
or transporting.
B. DAILY OPERATIONS
MAINTENANCE CHECKS:
1.
Battery
A. Check for corroded and loose terminals.
A white powder substance will be present if
there is any existing corrosion.
B. Visually inspect for any cracks or damage
to the casing.
C. Check for loose battery tie-downs.
2.
Charger
A. Inspect wire connections.
B. Check power cord for nicks/damage.
C. Check power charger for proper mounting.
3.
Hydraulic System
D. Inspect pump and cylinder for oil leaks.
E. Check hydraulic oil level.
G. Check ram for nicks/damage.
4.
Frame Assembly
A. Check chain roller assembly connections.
B. Check for any worn or damaged parts.
PRESTO OWNER’S MANUAL
Page 10
POWER STAK
DAILY OPERATOR CHECK LIST
CHARGE CONDITION/BATTERY CHECK LIST
1. Check Battery Discharge Indicator (Fuel Gage and Hour Meter) – Be sure unit is
showing proper Charge Level before operating unit
2. Check to be sure Charging Cord is Unplugged and properly stowed before operating unit
3. Inspect Battery Wire Connections – All connections should be tight with No Corrosion (white powder) showing at the Battery Terminals
4. Inspect Battery Case – There should be no cracks or visible damage to the Battery
Case
WALK AROUND INSPECTION
1. Check general condition of Stacker (loose or broken parts, oil, dangling wires, dents,
cracked covers etc.)
2. Check metal frame, mast, carriage and font load supports for cracked welds, worn or
missing hardware – bolts, nuts washers etc.
3. Check for evidence of hydraulic leaks
4. Make sure all precautionary labeling is in place and legible
FUNCTIONAL INSPECTION
1.
2.
3.
4.
5.
Check Drive – Forward and Reverse Function
Check Lift – Up and Down Function
Check Function for Belly Button Reverse
Check Horn Function
Check Brake Function
OPERATOR ID
DATE
DO NOT USE OR OPERATE STACKER IF ANY FUNCTION IS NOT
OPERATING PROPERLY OR IF STACKER APPEARS UNSAFE IN ANYWAY
REPORT CONCERNS TO SUPERVISOR IMMEDIATELY!
PRESTO OWNER’S MANUAL
Page 11
POWER STAK
SECTION 5
BATTERY MAINTENANCE
A. PREPARING TO CHARGE A BATTERY
1. Always turn off E-stop and key switch before working with the batteries.
2. Be sure the area around the stacker and the battery
is well ventilated while battery is being charged.
3. The battery terminals, connections and wiring
connections should be clean and free of corrosion.
When cleaning any of these components wear a face
shield or other suitable protective eyewear.
B. BATTERY CHARGING
Charging must be performed with the charger that is
provided with or prewired into the machine. During
charging, the temperature in the battery must not exceed
120 F. Charging simultaneously with truck operation is
not recommended. Plug the charger into a 115V outlet.
Charge until the battery gauge indicator lights show
fully charged (approximately 6-8 hours).
C. WARNINGS AND BATTERY INFORMATION
around freezing point, battery capacity is reduced by
30%. The battery terminals, connections and wiring
should be clean and free of corrosion. When cleaning
any of these components, wear a face shield or other
suitable protective eyewear. Read, understand, and folcautions while working with and/or charging batteries.
D. BATTERY MAINTENANCE
To measure the voltage, use a digital voltmeter (DC) on
the battery poles. The truck must not have been in use
for the previous 30 minutes.
DANGER
Never alter the AC cord or plug provided. If it will
risk of an electric shock.
1. Disconnect the charger from the 110 volt wall outlet once the indicators read fully charged.
Note: The batteries are designed for intermittent
use. Continual usage will wear the battery out and
charging will be required.
E. CHARGER OPERATION
Power Lamp
1. Green: Connection correct. Charger will operate
normally.
2. Red: Bad connection or bad battery.
Fault
1. Red light blinks 3 times in 5 seconds: The output
between charger is faulty, loose, or bad connection
2. Red light blinks 5 times in 5 seconds: The temperature is too hot for the charger to operate.
high. +- 10% is the general rule.
Charge Lamp
1. Red: Charger can charge normally. The battery is
less than 70%
2. Orange: Battery is between 70% and 100%
charged.
3. Green: BAttery is at 100%. Fully charged.
4. No light: The charger can not charge the battery.
Voltage of the battery may be too low to cause the charger to start. It must be at 9 volts to initiate charge.
VOLTAGE
PRESTO OWNER’S MANUAL
Page 12
Approx. 12.7 V
Fully charged
Approx. 12.2 V
1/2 charged
Approx. 12.0 V
1/4 charged
Approx. 11.6 V
Discharged
POWER STAK
1.
A. Clean terminals.
B. Clean battery compartment area if there are
signs of corrosion.
SECTION 6
MAINTENANCE
Operation of Presto Power Stak is very simple — as is
their construction. They require very little maintenance.
Reasonable care will result in excellent trouble-free
performance. The Power Stak is designed for one-man
operation and ease of performance.
a month
Use only Hydraulic Oil AW32 or Dextron III
in the hydraulic system.
Do not overload your lift.
Check brakes, steering mechanisms and controls before each use.
2.
3.
LEAKS: Check hydraulic system for leaks and hydrualic oil level.
WHEELS AND CASTERS: Check for wear and that
they are turning smoothly.
LIFT CHAINS: Check to see that they are in place
and not loose.
FORKS: Check that they are not bent or cracked.
BRAKES: Ensure brakes work properly.
Frame Assembly
A. Clean and lubricate all roller bearings, cam
followers and all moving parts.
B. Clean and inspect all welds.
C. Check wheels for wear and damage.
D. Inspect nameplate for legibility. Place the serial
and model number shown on the nameplate on
the cover of the manual for future reference.
MAINTENANCE CHECKS:
LIFT SYSTEM: Check to assure that there is no binding or excessive play in the forks. Check for quiet and
smooth operation of the lift cylinder. Check all moving
parts and linkage.
Hydraulic System
A. Clean and inspect hydraulic cylinder.
B. Lubricate chain with a rust inhibitive lubricant
(light machine oil).
C. Check chain tension. It should be even on both
chains. The chain should be tight enough so
that it does not come off of the roller assembly.
A. WEEKLY OPERATIONS
DAMAGE: Check for bent, dented, worn or broken
parts.
Battery (maintenance free)
4.
Electrical
A. Check batteries, motors, controllers, limit
switches, electrical conductors and connections.
CAUTION:
DO NOT USE LIFT IF IT IS NOT
OPERATING PROPERLY,
OR APPEARS UNSAFE IN ANY WAY!
SECTION 7
TROUBLESHOOTING
Before starting the troubleshooting, you have to:
A. Put the truck on an even and solid surface.
B. Turn off key switch or disconnect the battery terminals.
1. Unit will not lift (motor does not run)
CABLES; WIRES: Check that there are no loose
cables or wires.
LABELS: Ensure all precautionary labels and guards
are in place.
B. MONTHLY OPERATIONS
MAINTENANCE CHECKS:
PRESTO OWNER’S MANUAL
contactor to pump motor
¨ Pressure relief valve needs adjustment
Page 13
POWER STAK
¨ Pump check valve stuck open
¨ Faulty solenoid valve
stop button down.
3. Remove the 2 screws from the main orange cover
that covers the unit.
4. Remove the emergency stop button by unscrewing.
5. Slide the main cover up and place the block of wood
under the right hand side to hold open exposing the
idler wheel and adjusting the screw.
6. With the adjustable wrench loosen the jam nut on
the idler wheel adjusting screw.
2. Forks will not lower
3. No electrical power
Dead Batteries:
7. Loosen the adjusting screw until you have no tension between the adjusting screw and idler wheel.
You will have some play between the idler wheel
and the left front wheel.
8. Now tighten the screw until you just make contact
with the idler wheel. Continue adjusting until the
¨ Keyswitch on "OFF" position
¨ E-stop button depressed
¨ Loose or dirty battery connections
¨ Blown fuse(s)
9. Tighten jam nut. You may have a slight rocking
back and forth, from the left front to right rear idler
wheel, but this is not uncommon.
10. Now remove the wooden block and lower the cover
back into place inserting the 2 screws and tighten.
Screw the E-stop button back on.
11. Your adjustment is complete
contactor
If the wheel is worn, replace wheel.
4. No Traction
Idler wheel needs adjustment
IDLER WHEEL ADJUSTMENT
The following is a procedure for adjusting the idler
wheel on the Presto PowerStak. Under normal conditions this should not be necessary becaus the idler wheel
has been adjusted at the factory.
Tools Needed:
Phillips head screw driver
Medium crescent wrench
1 block of wood (2 x 4)
1.
2. Turn key to the OFF position and push emergency
PRESTO OWNER’S MANUAL
Page 14
POWER STAK
Figure 2:
PPS2200-62NAS
Exploded View
Prior to November 2008
1039
1040
1031
1032
1033
1055
3200
1056
1057
1047
1030
1034
1041
1042
1043
1044
1045
1046
1029
1035
1028
1036
1027
1037
1038
1023
1022
1058
1059
1060
1021
1048
1026
1025
1024
1020
2300
4000
1049 1050
1051
1052
1053
1054
1006
1007
1008
1002
1001
5000
6000
7000
8000
1004 2400
1003 1005
PRESTO OWNER’S MANUAL
1019
1018
1017
1009
1010
1011
1012
1013
1014
1015
Page 15
1016
POWER STAK
Table 1:
Prior to November 2008
Model PPS2200-62NAS
Item
2300
2400
3000
3100
3200
4000
5000
6000
7000
8000
1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1022
1023
1024
1025
Cylinder
Rear wheel
Drive wheel assembly
Handle assembly
Steering assembly
Electric system
Power unit
Body weld
Drive wheel cover
Rear box cover
Nut M6
Bolt M6x25
Spring washer 6
Bolt M6x25
Nut C-Grade M12
Leg assembly
Nut C-Grade M12
Bolt
Bolt M20x65
Nut C-Grade M20
Spring sleeve
Spring
Front wheel axle
Washer ? 20
Bearing 6204
Front wheel
Flat washer 12
Spring washer 12
Bolt M12x25
Chain wheel
Chain wheel axle
Qty
1
2
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
4
4
1
1
1
1
1
2
2
4
2
2
2
2
2
1
1
PRESTO OWNER’S MANUAL
Item
1026
1027
1028
1029
1030
1031
1032
1033
1034
1035
1036
1037
1038
1039
1040
1041
1042
1043
1044
1045
1046
1047
1048
1049
1050
1051
1052
1053
1054
1055
1056
1057
1058
1059
1060
Page 16
Bearing 6006
Washer
Washer ?30
chain wheel top base
Chain LH1234
Bolt M6x25
Flat washer 4
Spring washer 4
H bolt M4x12
Nut M10
Nut M10
Flat washer 10
Cylinder hoop
B-pin ?8x40
Pin ?2.5x12
Chain pole
Pin ?2.5x25
Flat washer 16
Nut M16
Nut M6
Spring washer 6
Bolt M6x25
Bolt M6x35
Spring washer 6
Flat washer 5
Cover lock plate
Round cover
Bolt M5x10
Flat washer 5
E-Stop
Key Switch
POWER STAK
Qty
2
2
1
1
1
2
4
4
4
2
2
2
1
1
2
1
1
1
1
1
1
1
2
2
2
2
2
2
1
1
2
2
1
1
1
Figure 3:
PPS2200-62NAS
Exploded View
November 2008 to Present
PRESTO OWNER’S MANUAL
Page 17
POWER STAK
Figure 4:
Cylinder View
PPS2200-62NAS
Prior to November 2008
PRESTO OWNER’S MANUAL
Page 18
POWER STAK
Figure 5:
Cylinder View
PPS2200-62NAS
November 2008 to Present
Item
5001
5002
5003
5004
5005
5006
5007
5008
5009
5010
5011
5012
5013
PRESTO OWNER’S MANUAL
Page 19
O Ring
Velocity Valve
Cylinder Barrel
Nut
U Ring
Piston
Spacer
O Ring
Piston Rod
Wearable Ring
Dustproof Ring
POWER STAK
Qty
1
1
1
1
1
2
1
1
1
1
2
1
1
Figure 6:
Prior to November 2008
Caster Wheel Assembly
PPS2200-62NAS
2401
2402
2403
2404
2405
2406
2416
2415
2414
2407
2413
2412
2411
2410
Item
2409
2410
2411
2412
2413
2414
2415
2416
Wheel 128x55
Bearing 6004
Wheel frame
Nut M14x1.5
Spring washer 14
Bolt M12x1.5-100
1-type Nut C-grade
Wheel plate
Qty
Item
1
2
1
1
3
1
1
1
2401
2402
2403
2404
2405
2406
2407
2408
PRESTO OWNER’S MANUAL
Page 20
2409
2408
Qty
Bolt M10x35
Spring washer 10
Nut M10
Bearing 51113
Bearing
Flat washer
Pin 3.2
Sleeve
POWER STAK
4
4
4
1
1
1
1
1
Figure 7:
November 2008 to Present
Caster Wheel Assembly
PPS2200-62NAS
Item
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
Bolt M12X40
Spring Washer M12
Flat Washer M12
Wheel Frame
Bolt M12X90
Wheel Side Cover
Bearing Ring
Wheel
Sleeve
Bearing
Nut M12X90
Qty
4
4
4
1
1
2
2
1
1
2
1
PRESTO OWNER’S MANUAL
Page 21
POWER STAK
PRESTO OWNER’S MANUAL
Page 22
POWER STAK
Figure 8:
PPS2200-62NAS
Drive Wheel Assembly
Figure 9:
Control Pod
PPS2200-62NAS
Item
7101
7102
7103
7104
7105
7106
7107
7108
7109
7110
7111
7112
7113
7114
7115
PRESTO OWNER’S MANUAL
Page 23
Qty
Screw M6X12
3
1
1
Electrical Outlet (big)
1
Electrical Outles (small) 1
1
Upper Cover
1
Spring
2
1
1
Right Handle Cover
1
Bolt M3X10
2
Washer
2
Switch Cover
1
Switch
1
POWER STAK
Figure 10:
Steering Assembly
Prior to May 2007
PPS2200-62NAS
Item
1100
1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1200
PRESTO OWNER’S MANUAL
Page 24
Qty
Handle
Handle joint pipe weld
Washer 8
Bearing Pin
Spring
Limited Switch
Washer C Grade
Bolt M5x28
Joint pipe pin
Nut M52x1.5
Nut washer 52
Handle joint base weld
Washer 18
Nut M56x2
Nut washer 56
Cover
Bearing 30212
Bearing sleeve
Bolt M10x30
Spring washer 10
Drive wheel 700W
POWER STAK
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
2
1
1
1
4
4
1
Figure 11:
Steering Assembly
May 2007 to August 2008
PPS2200-62NAS
Item
3100
3201
3202
3203
3204
3205
3206
3207
3208
3209
3210
3211
3212
3213
3214
3215
3216
3217
3218
3219
3220
3221
3222
3223
3224
3225
3226
3227
3228
3229
3230
3000
PRESTO OWNER’S MANUAL
Page 25
Qty
Handle
Handle pipe weld
Washer 8
Pin
Air spring
Cover lock plate
Bolt M6x25
Spring washer 6
Washer 6
Nut M6
Nut M4
Travel switch
Flat washer 4
Bolt M4x25
Short thread screw
Round nut M52x1.5
Lock washer 52
Handle base weld
Round nut M56x2
Lock washer ?56
Press cover
Bearing 6212
Bearing sleeve
Steering weld base
Washer
Spring washer 6
Bolt M6x12
Bearing 30212
Bolt M10x30
Spring washer 10
Drive wheel (700W)
POWER STAK
1
1
1
1
1
1
2
2
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
2
2
2
1
4
4
1
Steering Assembly
Figure 12:
August 2008 to Present
PPS2200-62NAS
Item
Qty
7100
Handle
1
7001
Handle Pipe Weld
1
7002
Snap Ring 8
1
7003
Holder
2
7004
Pin
1
7005
Spring Bearing
1
7006
Bolt M8X30
1
7007
Flat Washer 8
1
7008
Spring Washer 8
1
7009
Nut M8
1
7010
Washer
2
7011
Spring Washer 6
2
7012
Bolt M6X12
2
7013
Bolt M10X30
4
7014
Spring Washer 10
4
7015
Bearing 33013
1
7016
Bolt M10X30
4
7017
Spring Washer 10
4
7200
Drive Wheel (700W)
1
7018
Cover Holder
1
7019
Bolt M6X25
2
7020
Spring Washer 6
2
7021
Flat Washer 6
2
7022
Nut M6
2
7023
Nut M4
2
7024
Travel Switch
1
7025
Flat Washer 4
2
7026
Short Screw
2
7027
Bolt M4X25
2
7028
Round Nut M52X1.5
1
7029
Lock Washer 52
1
7030
Handle Connect Base
1
7031
Round Nut M56X2
1
7032
Washer
1
7033
Bearing 61812
1
7034
PRESTO OWNER’S MANUAL
Page 26
1
7035
Drive Wheel Holder
1
7036
A-Flat Key 8X45
1
7037
Steering Base Weld
1
POWER STAK
PRESTO OWNER’S MANUAL
Page 27
POWER STAK
P ASSY, QM MDLR, DC, BRGS BLD RSV
SCREW, SHC, 1/4-20 x 2.75, BLK OX
TUBE, RTN, STR, 1/8 NPT, NYLON
TUBE, SUCT, STR, 3/8 NPT, NYLON
FILTER, SCREEN M-SERIES SUCT.
RESV, PLSTC, 6.75x6.75x11, V/MT
CLAMP, HOSE, WORM GEAR, RSV, M-SER
PLUG, RESV, BREATHER-FILL, 3/4-14
MOTOR, DC, 12V, 4.5", 2 TERM
CABLE, INSULATED W/LUGS #4G 6"L
SWITCH, SOL ACT MTR ST, 24 VDC
WIRE ASSY, CNTRL, 16AWG, HS, RING
CARTRIDGE, 2W/2P, NC, POPPET, 4000
COIL, 24VDC, #8, TWO 1/4 MALE TAB
POPPET ASSY, P CMP FL, GPM 2.00
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
1
1
1
1
1
1
1
2
1
1
1
1
4
1
1
BASE ASSY M3519 MOD M10-1.5 SD
1
SCHEMATIC
1.67 CC/REV
0.102 IN /REV
Qty
!
172 BAR
2500 PSI
OUTLET PORT
9/16-18 SAE #6 REF
Item
Figure 13:
10
11
12
13
15
PPS2200-62NAS
1
9
2
3
4
5
6
7
VIEW SHOWN WITHOUT RESERVOIR
Prior to November 2008
2 MOUNTING HOLES
M10 X 1.5
2 MOUNTING HOLES
M10 X 1.5
8
BASE - 11763
DRAIN HOLE REF
14
Power Unit Assembly
7.57 LPM
2.00 GPM
OUTLET PORT
9/16-18 SAE #6
(PLASTIC PLUG)
GROUND SCREW HOLE
5/16-18 UNC-2B
RELIEF VALVE
16
November 2008 to Present
Figure 14:
Power Unit Assembly
PPS2200-62NAS
PRESTO OWNER’S MANUAL
Page 28
POWER STAK
Figure 15:
Carriage Assembly
PPS2200-62NAS
Item
4002
4003
4004
4009
4011
4012
4013
4014
4015
4016
4017
PRESTO OWNER’S MANUAL
Page 29
Nut M6
Bolt M6X30
Middle Plate
Adjustable Plate
Bearing 6307
Wheel Sleeve
Snap Ring M35
Snap Ring M80
Fork
POWER STAK
Qty
4
4
4
1
4
4
4
6
4
2
1
Figure 16: Labels & Precautionary Warnings
PRESTO OWNER’S MANUAL
Page 30
POWER STAK
5001
5002
5003
5004
5005
5006
MOSFET controller
Contactor F/R
Hydraulic Contactor
Fuse 150A
Fuse 5A
Horn
1
1
1
2
1
1
Prior to November 2008
Figure 17 Electric Control Parts
PRESTO OWNER’S MANUAL
Page 31
POWER STAK
Prior to November 2008
Figure 18: Electric Control Circuit
PRESTO OWNER’S MANUAL
Page 32
POWER STAK
Prior to November 2008
Figure 19: Wiring
Connectors viewed from wire entry side.
PRESTO OWNER’S MANUAL
Page 33
POWER STAK
Figure 20:
Prior to November 2008
PRESTO OWNER’S MANUAL
Page 34
POWER STAK
November 2008 to Present
Figure 21:
PRESTO OWNER’S MANUAL
Page 35
POWER STAK
November 2008 to July 2011
Figure 22:
PRESTO OWNER’S MANUAL
Page 36
POWER STAK
August 2011 to Present
Figure 23:
PRESTO OWNER’S MANUAL
Page 37
POWER STAK
November 2008 to Present
Figure 24:
PRESTO OWNER’S MANUAL
Page 38
POWER STAK
November 2008 to Present
Figure 25:
PRESTO OWNER’S MANUAL
Page 39
POWER STAK
Figure 26:
November 2008 to Present
PRESTO OWNER’S MANUAL
Page 40
POWER STAK
November 2008 to Present
Figure 27:
PRESTO OWNER’S MANUAL
Page 41
POWER STAK
November 2008 to Present
Figure 28:
PRESTO OWNER’S MANUAL
Page 42
POWER STAK
November 2008 to Present
Figure 29:
PRESTO OWNER’S MANUAL
Page 43
POWER STAK
Table 2:
RECOMMENDED SPARE PARTS LIST
PPS2200-62NAS
Qty
1
1
4
1
1
1
1
1
1
1
1
1
2
2
Part No.
80004251
PPS-1005
PPS-3110
PPS-3115
PPS-5004
10049242
PPS-5002
PPS-5003
PPS-2016
10039318
PPS-3030
Serial number req.
PPS-AS/FS-2021
PPS-AS-FS-2023-2022
PRESTO OWNER’S MANUAL
Description
Shock-air spring piston
Limit Switch at handle
Switch, raise/lower
Switch, forward/reverse
150A fuse (hydraulic power unit)
100A/125A fuse (Traverse)
Forward/reverse contactor
Contactor, main, for lift
Battery charger
Battery charger cord
Brake kit (Brake & Gear)
Swivel caster assembly
Load wheel axle
Load wheel with bearings
Page 44
POWER STAK
Ordering Replacement Parts
Presto Lifts has carefully chosen the components in your unit to be the best available for the purpose.
Replacement parts should be identical to the original equipment. Presto Lifts will not be responsible
for equipment failures resulting from the use of incorrect replacement parts or from unauthorized
Presto Lifts can supply all replacement parts for your lift. With your order, please include the model
is located within the cabinet, or the angle iron cylinder cross support.
To order replacement parts, please call the Presto Parts Department. Parts are shipped subject to the
following terms:
Freight - prepaid and invoice for small parcel shipments (except parts covered by warranty).
replacement part, then credit you when you return the worn or damaged part.
Presto Lifts Parts Department
21 Park Street, Attleboro, MA 02703
Telephone: 800-343-9322
FAX: 888-788-6496
Email: [email protected]
www.PrestoLifts.com
PRESTO OWNER’S MANUAL
Page 45
POWER STAK
RESTOCKING POLICY
PARTS
are not returnable. Unfortunately, due to potentially concealed damage, all sales of electrical
QUALITY ISSUES
Should you feel there is a quality problem, please contact the seller to ask questions and gather
information on how to rectify the issue. Presto Lift Inc. reserves the right to determine potential
credits, as a result of factory defects, based on its inspection of the merchandise.
GENERAL
All products shipped from our factory have passed Quality Assurance inspection and testing.
The carrier of choice has signed for, and accepted the product in new working condition. The
customer should inspect to ensure it is not received damaged, has no concealed damage or is not
incomplete. Parts orders are determined to be complete based upon Presto Lift, Inc. inspection
sheets and carrier shipping weights.
PRESTO OWNER’S MANUAL
Page 46
POWER STAK
RETURN GOODS AUTHORIZATION POLICY
courtesy to our distributors in the event they do not receive what they ordered. If a customer
wishes to return a Presto Lifts product, please contact the Customer Service Department and
following the date of Presto Lifts’ invoice for the merchandise. Not all units are returnable.
Quantity orders and special designs cannot be returned under any circumstances. Presto Cus-
The RGA number must appear on the outside of any packaging material for a return to be accepted and processed by Presto Lifts. Customers shipping returns from the Continental US,
Canada, or Mexico have thirty (30) days from date of RGA issue to have the product arrive at
Presto Lifts’ facility. All merchandise must arrive Free on Board at Presto Lifts’ facility or the
shipment will be refused and returned to the sender. All credits are issued less restocking and
refurbishing charges, regardless if the merchandise was damaged in transit.
Return addresses: please refer to your RMA for the address to which your product should be
returned.
Presto Lift Inc.
715 Highway 77
Manila, Arkansas 72442
Telephone: 800-343-9322
Fax: 888-788-6496
PRESTO OWNER’S MANUAL
Page 47
POWER STAK